Forging means



Jall- 14, 1936' G. sPA'rTA 2,027,406

FORGING MEANS Original Filed Feb. 21, 1930 6 Sheets-Sheet l Inde/@25W Jan. 14, 1936. G, SPATTA 2,027,406

` FORGING MEANS original Filed Feb. 21, 19:50 e sheets-snaai 2v Mw@ n G. SPATTA FORGING MEANS Jan. 14, 1936.

Original Filed Feb. 21, 1930 6 Sheets-Sheet 3 NAN.

Jan. 14, 1936. Q SPATT'A 2,027,406

FORGING MEANS Original Filed Feb. 21, 1930 6 Sheets-Sheet 4 ifm Ml lt/mais eofyetaaz/ j? 155, f l mi 6 Sheets-Sheet 5 G. SPATTA FORGING `MEANS original Filed Feb. 21, 1930 Jan. 14, 1936 5 SheelcS-Sheet 6 Original Filed Feb. 2l, 1930 v '.:ggg I I I I I Jan. 14, 1.936.

Patente-d4 Jan. 14, 1936 j UNITED STAT 'PATE-Nfl" Ori-*Ica FORGINGMANS lGeorge Spattaflluclianan," Mich., assigner to Clark Equipment Company, Buchanandliich., a corporatlonof Michigan V x Application February 21,` 1930, Serial Renewed March 1,119.35

6 Claims, (Cl. '1B-63) f.

This invention relates to means for forging the The present invention relates specifically to a step in the method outlined in the above mentioned copending application, the particular step performing the langing operation on the ends of the housing to form a receptacle for the bearing by which the axle is supported in the housing and a mounting plate for the brake drums that are to be mounted on the housing.

The .forging of the ends of the blank from which the housing is made occurs after the banjo section of the housing has been formed and finished, and the operation is therefore one of the last to be performed on the blank during its f abrication. The method of forming the step in the operation of forming the flanges on the end of the tubular blank is disclosed in my copending application Serial No. 534,747, filed May 4, 1931,

which is a division of the instant application and to which application reference is here made for those details.

The end of the blank is heated to forging temperature, and it is then inserted in a forging machine. The blank is preferably` gripped by a clamping member engaging the tubular part of the blank between the throat of the banjo section and the end that is to be forged. With the blank so gripped in the machine, the heated end section that is to be forged projects into a stationary die disposed with its axis in alignment with the axis of the gripping member.

-A movable punch registering with the die is advanced to engage the blank and shape it in accordance with the external contour of the punch and the internal contour of the die. The clamping member is then released and the blank y dropped to a second clamping memberwhich is closed to engage the same tubular part of the blank. The end of the blank again projects into al stationary die and a movable punch is brought into registration with the blank and die to perform a second step of the forming operation. After the second step is completed, the blank is dropped into a third clamping member which is closed about the tubular portion of the blank, and a movable punch is brought into registration with the blank and the stationary die to perform the third and finishing operation on it.

The gripping of the tubular part of the blank adjacent the point that is to be forged is depended on to prevent the blank from slipping in the die during the forging operation.

For this reason the clamping members are accurately formed to conform to the external contour of the cylindrical part of the blank, and are closed with sufficient pressure to firmly clamp the housing. The pressure exerted on the blank by the clamping member is exerted radially of v ythe blank and is applied completely around the circumference of the blank so that there 'is no danger of crushing the walls of the tubular section engaged by the clamp.

By proper design of the machine and positioning of the clamping members and dies so that they are readily accessible and the heated blank can be quickly inserted into them, I am able to perform the three forging operations on the blank before it has cooled sufficiently to necessitate its being reheated. This, of course, reduces the total time required for the completion of the axle housing and makes the cost of the operation reasonably low. v

In the preferred embodiment of the machine the clamping members and dies are formed into sections, one of which is stationary and firmly attached to the frame work of the forging machine. The other section of the dies and clamping members is mounted in a movable ram which moves transversely of the longitudinal axis of the clamping member in a motion that maintains the face of the movable member adjacent the Working face of the stationary member always parallel to it. f

The die ram is moved by a mechanical cam and lever arrangement, although this movement may be accomplished in any other preferred manner such as by a hydraulic means.

The movement punches are carried on a horizontally movable ram capable of motion longi- -tudinally of the axis of the gripping member and operated by mechanical means in the preferred embodiment of the invention. If desired, the -die carrying ram may also be operated in any other preferred manner such as by a hydraulic means.

The dies and punches employed in this operation must, of course, be diierent for every type and size of axle housing forged in the machine, that is there must be a set of punches and dies for each type of axle housing made in the shop. It is therefore imperative that the die structure and punch structure be of a design that permits them to be easily removed from the set up in the machine, so that when it is necessary to change the machine to make a different type of,

axle housing, the change can be made with a minimum of lost time.

Further objects of the invention will be best understood from a reading of the detailed description and claims which follow.

Now, to acquaint those skilled in the art with the teachings of my invention, reference is made to the accompanying drawings in which a preferred embodiment of it is shown by way of example and in which:

Figure 1 is a plan view of the completely assembled forging machine with the die structure in its open position;

Figure 2 is a cross-sectional View taken substantially along the line 2--2 of Figure 1 showing a blank in its rst position in the machine and with the punches in their normal position;

Figure 3 is a view similar to Figure 2 showing the punches in their closed position engaging the blank;

Figure 4 is a View similar to Figure 2 showing the blank in the second die and showing the punch in its closed position engaging the blank;

Figure 5 is a view similar to Figure 2 showing the blank in the third die and the punch closed in engagement with that blank;

Figure 6 is an elevation view partly in section of the end of the movable ram showing the punch holders in place in it;

Figure 7 is a detail view of the punch employed in the first step of the process;

Figure 8 is a detail view of the punch employed in the second step of the process;

Figure 9 is a detail view of the punch employed in the third and last step of the process;

Figure 10 is a sectional elevation taken along the line lll-lil of Figure l showing the die and clamping structure in its open position;

Figure l1 is a view similar to Figure 10 showing the die and clamp structure in its closed position; A

Figure 12 is a cross-sectional view taken along the line I2--l2 of Figure 10 looking in the direction of the arrows; l

Figure 13 is a cross-sectional view taken along the line I3-l3 of Figure 10 looking in the direction of the arrows;

Figure 14 is a cross-sectional View taken substantially along the line I4--I4 of Figure 6 showing the method of locking the punch in the punch holder;

Figure l5 is a plan view showing the blank at the end of the rst stage of the operation in solid lines and at the beginning of the rst stage of the operation in dotted lines;

Figure 16 is a cross-sectional view of the blank showing the punch at the end of the first step of the process;

Figure 17 is a plan view of the blank showing it at the end of the second step in solid lines and at the beginning of the second step in dotted lines;

Figure 18 is a cross-sectional view through the blank shown in Figure 17 showing the punch at the end of the second step in the process;

Figure 19 is a plan view of the blank showing the flange at the end of the third step in solid lines and at the beginning of the third step in dotted lines;

Figure 20 is a cross-sectional view through the blank shown in Figure 19 showing the position of the punch at the end of the third step of the process;

Figure 21 is a plan view of the blank showing it at the end of the rst step of the process;

Figure 2'2 is a plan view of the blank at the end of the second step of the process; and

Figure 23 is a plan view of the blank showing it at the completion of the third step in the process.

Referring to the drawings, now, in more detail, the machine comprises a framework I which is a clevis-like framework disposed with its open end upward. At the front end 2 of this framework are located the stationary die 3 and the movable die 4, together with the link mechanism indicated generally at 5, through which the movable die 4 is moved in a horizontal direction towards the stationary die 3.

In the back part of the machine, the main crank shaft 6 is supported in suitable bearings l and 8y and arranged to be driven by the gear 9 which meshes with the pinion I0. The pinion is keyed to the shaft II which runs transversely of the frame of the machine to the fly-wheel and clutch i2. An electric motor, not shown, is geared to the ily-wheel and clutch by a shaft I3 to drive the press.

The shaft 6 contains the crank arm I4 which is connected by connecting rod I 5 to the movable ram i6 which ram carries the punches II in the manner which will be hereinafter pointed out. The shaft 6 also carries a cam I8 which engages the roller I9 through which the lever arrangement 5 is operated to close the movable die 4 against the stationary die 3.

The open ends of the framework of the machine are braced by rods 20 and 2I which are bushed in suitable bushings 22 and fastened therein in any preferred manner to enable them to hold the open end of the framework of the machine rigidly in place against the reactions set up by the operation of the movable ram I6.

The clutch which is included in the fly-wheel I2 is operated by a foot lever 23 located at the front side of the machine, this clutch being any preferred type of clutch capable of operating the machine through an entire cycle each time the foot lever 23 is pressed.

As shown, the lever 23 mechanically controls the clutch, this showing being made by way of example only, as any preferred type of control, such as a hydraulic or an electric control, may be substituted for the mechanical control shown, particularly since this feature is not of the essence of the present invention.

In the operation of the machine, the blank is placed against the stationary die, the machine is operated to move the movable die 4 against the blank to clamp it between that die and the die 3, and the ram I6 is moved forward in a horizontal direction to bring the punches I1 into engagement with the blank in the die.

Should the forces set'up in the die structure exceed the maximum that the machine is capable of resisting, the lever and link arrangement 24 operates against the tension of the spring 25 to permit the toggle 26 to open and Withdraw the movable die 4 from engagement with the stationary die 3, thereby releasing the work from the machine to prevent damage to the machine. The particular type of overload release shown in the drawings is old and well understood by those skilled in the art and is not of the essence of the present invention.

As will be best seen in Figures 2 to 6, the ram v I6 is of generally rectangular cross-section and iits in the slot 30 in the framework I of the machine.

The ram I 6 contains a. rectangular slot 3| which posed horizontally in the ram and an upwardlyprojecting portion disposed at one of its ends. That is, the die holder 34 is provided with a projection 35 which fits against the back surface 36 of the slot 3|, projecting slightly above the top surface of the ram. 'I'he die holder 33 is provided with asimilar projection 31 which ts against the projection 35 of the holder 34, and the holder 32 is provided with a projection 38 which nts against the projection 31 of the holder 33.

The projections 35, 31 and 38 all extend above the upper surface of the ram, and are held in the ram by the plates 48 and 4| which are attached to the ram by bolts 42 and fitted over the open upper side of the slot' 3| and against the projection 38 of the holder 32. By this arrangement the punch holders are securely held in the ram but at the same time they are readily removable therefrom.

The punch holder 32 is provided with a cylindrical slot 43 in the end of which is a counterbore 44, the diameter of the counterbore' being larger than that of the slot 43. Similarly, the holder 33 is provided with a'cylindrical slot 45 and counterbore 46, and the holder 34 with a cylindrical slot 41 and a counterbore 48. 'I'he counterbores serve as lsockets into which the tongue portions of the punches are registered and held in the manner that will presently appear.

As will be seen in Figures 7, 8 and 9, the punches 58, 5| and 52 are provided with cylindrical tongue portions 53, 54 and 55, respectively. The tongue portion 53 of the punch 58 is provided with two wedge shaped slots 58 and 51 which are disposed with their deep end towards the body portion of the punch 58 and their shallow end toward the free end of the tongue 53. Similarly, the tongue 54 of the punch 5| is provided with a pair of wedge shaped slots 58 that are similarly located, andthe tongue 55 ofthe punch 52 with a pair of wedge shaped slots 59 also located in the same manner.

As will be seen in Figures 3 and 14, the tongue 55 of the punch 52 fits into the counterbore 48 and set screws 88 and 6| are projected through the holder 34 at an angle normal to the surface of the wedge shaped slot 59 in the tongue. By tightening the set screws 68 and 5| against the surface of the wedge shaped slot 59, the tongue 55 is drawn into the counterbore and the punch thereby securely fastened in the punch holder. The punch` 52 is provided with a hardened forming plate 53 through which the tongue 55 extends, and this plate is also held in position on the surface of the holder .by the set screws 58 and 5i and their engagement with the tongue 55.

The punches 58 and 5| are held in the holders 32 and 33, respectively, by set screws, not shown, 'similarly projected and engaging the sloping surfaces of wedge shapedslots 53, 51 and 58.

The working end of the punch 58V is provided with a conical portion 84, the shape of which conforms to the desired shape of the interior surface of the blank, and the working end of punch 5| is similarly provided with a formed conical section 55, and the working end of punch 52 with a conical section 56, both 0f which conform to the shape to which it is desired to form the interior surfaces of the blank that is to be operated on in the machine.

As will be seen in Figures 1, 18, 11, 12 and 13,

v screws 11.

the die comprises a stationary die member 18 which is tted into the rectangular socket 1| in the framework l, and the movable member 12 which is supported on the transversely movable ram 13 which in turn is supported in the slot 14A in the framework l.

In one end of the stationary die is a hardened insert set in a pocket 18 and held therein by A clamping slot 18 and a forming slot 19 are formed in the flat working surface of the die 18 and forming block 15, respectively. I'hese slots constitute one half of the clamp and forming die, respectively.

The other half of the clamp and forming die is formed in the member 12, the hardened forming block 88 being held therein by screws 8|`in a manner similar to which the insert 15 is held in the die block 18. A clamping,` slot 82 and a forming slot 83 are likewise formed inthe work- I ing surface of the movable die 12, and when that die is closed againstthe die 18, the slot 82 cooperates with the slot 18 to form a cylindrical opening of dimensions equal to the external dimension of a tubular portion of the blank that is to be forged in thel machine.

.The forming slot 19 cooperates with the forming slot 83 to form the external surface of the the blank may also be gripped when the blank is inserted in the die formed by members and 85. As will be best seen in Figures 10 and 13, a stationary die block 92 is located below the stationary die block 18, and a movable die block 93 is similarly located below the movable die block 12. In the die blocks 93 and 93 are the hardened metallic inserts 98 and 9|, respectively, being held A therein by screws 94 and 95. It will be observed that the hardened inserts 98 and 9| are shorter than the inserts 15 and 80, this arrangement being preferable since the blank has been shortened by the operation performed on it before it is positioned in the lower die. The lower die is also provided with slots 98 in the stationary block 92, and 91 in the stationary block 93 which, together, form a cylindrical slot that exerts radial pressure onthe blank to hold it in the die during the forging operation.

The entire reaction set up in the blank in opposition to the pressure exerted on it by the moving punch is transmitted to the die block through the gripping action of the clamping members and the tubular portion of the blank.

It is therefore necessary that the clamping members be securely fastened in place in the machine against the likelihood of longitudinal displacement under the force of this reaction.,V To this end, the lower die members 92 and 93 are provided with transversely disposed rectangular slots |88 and |8| into which are fitted rectangular keys |82 and |83, which, together key the die blocks to the mounting plates upon which they are located. In the embodiment of the invention shown, spacing blocks |84 and |85 are located beneath the dies 92 and 93, these blocks being keyed to the machine in a similar manner by keys I 06 so that each'spacing block is thereby securely locked in place in the machine.

The upper surfaces of the dies 92 and 93 are likewise provided with transverse rectangular slots in which the keys |01 and |08 are located and registered with transverse rectangular slots in the die blocks 10 and 12, respectively, to hold those blocks in fixed relation with respect to the die blocks 92 and 93. The upper die blocks 10 and l2 are held down on the lower die blocks in any convenient manner, such as by brackets ||0 which are clamped down on the stationary portion of the machine and the top of the dies by bolts this arrangement securely holding the dies in place and at the same time permitting their ready removal when the occasion arises.

In the operation of the machine, the blank |20 is placed in the upper die and positioned therein by bringing that portion of the perimeter of the banjo |2| furthermost from the end of the blank being operated on into engagement with the guide pin |22 located on the forward part of the machine. This engagement with the guide pin |22 determines accurately the distance at which the bearing seat and brake plate are formed with respect to the center of the banjo of the axle housing, so as to insure that the operations performed upon the two ends of the' blank will be equally spaced from the banjo portion of the housing. This prevents any inequality in the formation of the blank, and provides for proper alignment thereof.

The machine is then operated to move the movable die structure, consisting of dies l2 and 93, in a horizontal direction to cause the clamping members of that die to engage the tubular portion |23 of the blank and thereby securely grip it by radial pressure exerted on the walls of the blank. 'I'he machine is then operated to cause the ram i6 to advance and bring the punch 50 into engagement with the end of the blank, that end being disposed within the die inserts 15 and in the die block. The end `64 of the punch fits inside of the tubular blank and through the operation of the punch the end section |24 of the blank, Figure 15, is upset back to form a thickened wall section |25.

-The diameter of the die is slightly greater than the diameter of the blank |20, and the outside diameter of the thickened end portion |25 is increased slightly by this operation.

When the ram I6 has completed its forward movement and brought the punch 50 into registration with the die, the ram reverses and travels back into the position in which it is shown in Figure l. The movable die is then backed oiI away from the stationary die and the `blank dropped down into the second die structure in which it is shown in Figure 4. The movable dies are again advanced to close against the cylindrical section |23 of the blank and the ram I5 is again advanced to bring the punches into registration with the die.

As will be seen in Figure 17, the punch 5| engages the thickened end portion |25, shown in dash-dot lines in the figure, and folds the metal in that section outward to form a flange |26. A portion of the metal inside of the blank |23 is pushed inward by this operation to extend the increased thickness of the wall inward of the blank as shown at |21.

When the punch has completely registered with the die, the movement of the ram is again reversed and the movable die again operated to open the die structure and release the clamped blank therefrom. The blank is then lowered and its banjo registered with the pin |28 to properly position it in the lower die of the machine. The ram I6 is again advanced to bring the punch 52 into registration with the blank, this operation expanding the flangev |26 of the blank outward to form a flange |29 which is thinner and of larger diameter. The forming block 63, which is held on the punch holder by the punch 52 in the manner hereinbefore explained, engages the flange |26 to form it into the flange |29 andI since this member 63 is hardened and ground f smooth, the outer surface |30 of the flange |29 is finished flat and smooth.

The punch 52 presses the wall of the blank out into the die to form the collar portion |3| which is joined onto the tubular portion |23 of the 'blank by a conical section |32, and the wall adjacent this conical section is thickened slightly as shown at |33.

After the punch has been brought into registration with the die, the movement of the rarn is again reversed and the movable die backed off to release the blank from the machine.

This completes the forging of one end of the blank. The other end is then heated and the same operations performed on it.

This arrangement of punches and dies leaves the dies and clamping members readily accessible so that the blank may be quickly inserted in them, and the operation of the punches is sufiiciently rapid to permit performing the three steps outlined during one heat of the blank, that is,

the steps are performed in sui'lciently rapid suc- .,:i

cession that all may be completed before the blank has had time to cool down sufficiently to require reheating to the proper forging temperature.

While I have chosen to show my invention in connection with a particular adaptation of it, I have done so by way of example only, as there are many modifications and adaptations which can be-made by one skilled in the art without departing from the teachings of the invention.

Having thus complied with the statutes and shown and described a. preferred embodiment of my invention, what I consider new and desire to have protected by Letters Patent is pointed out in the appended claims.

What is claimed isz- 1. In a forging machine, a movable ram containing a rectangular slot that is open on the end and top, a punch holder in the slot having a rectangular portion in the bottom of'it and proi jecting through its open end and a projection extending over the closed end of the slot, a second punch holder tted in the slot and against the rst holder and its projection, said second holder also having a projection disposed against the first, a third holder fitted in the slot against the second and having a projection disposed against the projection of the second holder, plates on the ram spanning the open top of the slot and lying against the third holder and its projection to bind the holders in the ram, a punch secured in each holder, and a stationary die for each punch with which it registers when the ram is moved to one of its extreme positions.

2. In a forging machine, a horizontally movable ram having a slot opening towards its free end and top, an L shaped punch holder disposed in said slot with its short portion against the closed end of it, a second L shaped -holder nested in the first with itsy short portion against the K 2,027,406 t short portion of the mst, a third l. shaped 'holder nested in the second with its short portion against the short portion of the second, means for holding said holders securely in the ram, and

a punch in each holder.

3. In a forming machine, a ram having a. deep narrow slot therein, a plurality of working dies stacked one on top of the other in said slot, means associated with the respective dies for holding the dies against relative movement in the slotv in at least one direction, and a plate across the top of the slot and cooperating with the top die to 'hold it against movement in the opposite direction, whereby the lower dies are held against movement in said opposite direction.

4. In a machine for upsetting the ends of the tubular arms of axle housings having' a. central enlarged banjo portion provided with an intermediate circular opening having its axis normal to the axis of said arms, a stationary die block, a second die block movable laterally against said first block to clamp one end of one of said arms therebetween, a die member having a punch portion adapted to be moved into register with said die blocks to upset the gripped end of said arm,

` and means spaced from said die blocks and engaging the remote portion of the periphery of said banjo opening to limit inward movement of said arm into engagement with said die blocks.

5. In a' machine for upsetting the ends of the tubular arms of axle housings having central `transverse openings, a stationary die block, a second die block movable against 'said first die block to clamp one end of said arms therebetween, 5 a die member having a punch portion adapted to be moved into register with said blocks to upset the gripped end of said arm, and means spaced. from the die blocksand engaging the dening wall of said opening to limit the position of said arm within said blocks whereby said upsetting operation Will be performed at a predetermined distance from the center of said opening.

6. In a machine for upsetting flanges at the ends of the tubular arms of axle housings having central transverse openings, a stationary die means, a second die means movable against said -flrst die means to clamp one end of said arms therebetween, a die member having punch means adapted to be moved into register with said die means to form a radial flange at the gripped end of said arm, and means spaced from the die means and engaging the dening wall of said opening to limit the position of said arm within said diemeans to gauge the distance from the center of the opening at which the radial flange will be formed, whereby each ange will be formed at a predetermined distance from the center of said opening.

. GEORGE SPATTA. 

